Invacare® Tornado SERVICE MANUAL
Contents
1. 2 and 4 as a spacer so that the belt mounting can rotate freely e Replace the safety belt 1 Refitting the safety belt e Refit the parts in reverse order 532. cable layout In case the cable layout is not flexible enough the cable binders can be opened e Remove all pole caps from the poles e Unscrew the screws 1 on the minus poles using an 11mm open jawed wrench e Unscrew the screws 2 on the plus poles using an 11mm open jawed wrench Loi CAUTION Danger of crushing e The batteries are very heavy Please ensure that they do not hit the ground when being removed from the chassis 32 e Pull the battieres out to the front using the carrying belt Loi CAUTION Fire hazard Cables can be pinched and chafed Please ensure correct cable layout They may not protrude into the lifter area Use cable binders if necessary When installing new batteries make sure there are no cables between the front batteries and the actuator of the lifter They could get damaged when the lifter is operated WRONG RIGHT e Installation is carried out in the reverse order Please note The battery inserters can be inserted between the battery and the carrying belt They are thus easier to install Please note The battery poles on the rear battery must point backward and those on the front battery to the front The batteries cannot be connected in any other fitting direction 33 34 Assemble in accordance with this installation sequence Push the batteries 3 together with the carrying belt 5 and battery inserter 4 into the c
3. particular tipping stability for this standard drive programme Tightening torques The tightening torques stated in the following table are dependent on the thread diameters for the nuts and bolts for which no special values are determined All values apply to dry and grease free threads Thread M4 M5 M6 M8 M10 M12 M14 M16 Tightening torque 3 NM 6Nm 10Nm 25Nm 49Nm 80 Nm 120 Nm 180 Nm in Nm 10 Caution All other nuts or plastic connectors not noted here must be tightened FINGERTIGHT 11 4 Layout of components and modules The following image shows the Tornado from above rear with the seat lifter raised and the rear cowling removed 1 Seat tilt actuator 2 Seat frame rear cowling anti collision P switch Speed reduction switch Power module CLAM Combined Light and Actuator Module Cable loom connectors 2 Seat lifter and tilt actuator end position switch Speed reduction switch Seat frame rear cowling anti collision switch 12 The following image shows the Tornado from the front right with the lifter raised 1 Lifter actuator 13 5 Service plan 1x annually zent omen em Ir e Armrests and side panels Seat unit seat angle adjustment Backrest unit mechanical Backrest unit electrical Wheel suspension and wheels Drive units disengager Electrical footrests Lighting 14 Armrest damage and fa
4. screwdriver TX40 e Remove the wheel from the hub e Unscrew valve cap e Let the air out of the tyre completely by pressing the pin in the centre of the valve in e Remove the 5 cylinder head screws back of the wheel 2 using the Allen key e Remove the rim halves from the tyre e Remove the inner tube from the tyre e Repair inner tube and replace or insert a new one NOTE If the old inner tube is to be repaired and re used and has become wet during repair you can make replacement easier by sprinkling the inner tube with a little talcum powder NOTE Re assembly is done in reverse order Ensure that the tyre is replaced on the same side and in the same travel direction as it was previously mounted e Insert the wheel rim halves from outside into the tyre e Pump a little air into the inner tube e Insert the cylinder head screws in the rim and tighten the wheel rims firmly Make sure the inner tube does not get pinched between the rims halves e Ensure that the tyre outer is seated correctly e Pump the tyre up to the prescribed pressure e Check that the tyre is seated correctly once again e Screw the valve cap back on e Refit the wheel 51 7 14 Gi s e 52 Replacing a drive wheel CAUTION Danger of the wheelchair tipping over or rolling away e Secure the wheelchair from tipping over by propping it up with a wooden block under the battery box that is lo
5. status display stops flashing If at all possible only drive when the seat is at driving height 3 Fault in left hand motor e Check plug in See Checking the Connection connections cables on page 38 loose defective or motor i P defective e Replace motor See Replacing the drive motors on page 25 4 Fault in right hand motor e Check plug in See Checking the Connection connections cables on page 38 loose defective or motor e gt defective e Replace motor See Replacing the drive motors on page 25 5 Fault brake fault on left e Check plug in See Checking the hand motor Connection connections cables on page 38 loose defective or motor P i defective e Replace motor See Replacing the drive motors on page 25 6 Fault brake fault on right e Check plug in See Checking the hand motor Connection connections cables on page 38 loose defective or motor A l defective e Replace motor See Replacing the drive motors on page 25 7 Battery dead e Pre charge battery See User Manual 19 20 FLASHCODE MEANING SOLUTION DOCUMENTATION 8 Battery voltage too high e Switch lights on to See User Manual of lower battery the charger voltage e Check battery charger 9 or 10 Faulty data transmission e Remove all between modules electronic modules except the Power Module and the Remote Re attach modules one by one to determine which one is causing the fault See Replacing component
6. 0 36 38 Page 7 7 Replacing the ACS Remote 7 8 Updating the driving program 7 9 Testing an actuator motor 7 10 Adjusting and replacing the speed reduction switch 7 11 Replacing the steering head bearings on the front or rear castor wheels 7 11 1 Front Castor Wheels 7 11 2 Rear Castor Wheels 7 12 Replacing the Anti Dive Spring and or its plastic guides 7 13 Repairing a flat tyre 7 14 Replacing a drive wheel 7 15 Replacing the safety belt 39 41 42 43 44 46 48 50 52 53 1 1 1 2 gt Bs Introduction General information e All maintenance and overhaul work must be carried out in accordance with these repair instructions e Please observe all safety instructions e Information about operation or about general maintenance and care work should be taken from the electric vehicle Operating Manual e You can find information about ordering spare parts in the spare parts catalogue e Use only genuine Invacare spare parts Using parts from any other source will void the warranty e We reserve the right to make any alterations on the grounds of technical improvements e The electric vehicle may only be maintained and overhauled by qualified personnel e The minimum requirement for service technicians is relevant training such as in the cycle or orthopaedic mechanics fields or suitably long term job experience Experience and knowledge of electrical measuring devices Multimeter is als
7. Invacare Tornado SERVICE MANUAL eee CE This manual contains information on Troubleshooting Maintenance Repair Version 26 11 09 Mobitec Mobilitatshilfen GmbH 43 6232 55 35 0 i Ad Sg Herzog Odilostrasse 101 Fax 43 6232 55 35 4 A 5310 Mondsee office mobitec austria com Austria austria invacare com WWW www mobitec austria com CR Invacare n v a 32 0 50 83 10 10 Autobaan 22 Fax 32 0 50 83 10 11 CL B 8210 Loppem Brugge belgium invacare com Belgium WWW www invacare be CH Mobitec Rehab AG a 41 0 61 48 77 08 0 Benkenstrake 260 Fax 41 0 61 48 77 08 1 CH 4108 Witterswil office mobitec rehab ch Switzerland switzerland invacare com WWW www mobitec rehab ch Th Invacare Aquatec a 49 0 75 62 7 000 Alemannenstrae 10 Fax 49 0 75 62 7 00 66 88316 Isny info invacare aquatec com Deutschland WWW www invacare aquatec de DK Invacare A S Kundeservice 45 0 36 90 00 00 AAA Sdr Ringvej 37 Fax Kundeservice 45 0 36 90 00 01 DK 2605 Br ndby denmark invacare com Danmark WWW www invacare dk E Ej Invacare SA T 34 0 972 49 32 00 el Areny s n Fax 34 0 972 49 32 20 Pol gon Industrial de Celr contactsp invacare com E 17460 Celr Girona WWW www invacare es ESPA A FD Invacare Poirier SAS a 33 0 247 62 64 66 Route de St Roch Fax 33 0 247 42 12 24 F 37230 Fondettes contact
8. been fixed may the fuse be replaced Check the battery cables 2 in their entirety for damage If damaged replace them If the battery cables are not damaged then the cause may be a short circuit inside the aS power module 3 partially hidden by cables d 4 in the picture This is not necessarily visible N A from the outside In this case exchange the ima power module for another one to determine whether this is the cause Loosen and remove the nuts that hold the fuse with the 8mm combination wrench Insert a new fuse re position the nuts and tighten Close the lid of the fuse compartment Reassemble all parts in reverse order Test all wheelchair functions to make sure everything is working properly 37 E Gi een e 38 Checking the cables Find out here how you can check the plug connections on the Tornado electronics CAUTION Cables can pull off e Remove the electronic panelling carefully on vehicles with a lighting system so that the cables are not pulled off the light circuit board The connectors do not have to be removed Pre requisites e Large flat screwdriver Please note Use the screwdriver carefully in order to avoid scratches on the panelling e Move the lifter to the uppermost position e Remove the electronic panelling In doing so press the cover out of the rear side panelling on one side using a large flat screwdriver e Check all cables for s
9. ct value ACS System 50 A Shark 40 A e Ifthe main fuse is burnt out then the cause must be fixed before inserting a new fuse Requirements e Combination wrench 8mm e Spare fuse e Large flat bladed screwdriver Note If the fuse holder is damaged it can replaced together with the battery cables Always be careful not to damage or scratch the cover on the electronics compartment when using a screwdriver to help open it WARNING Danger of damage to wires and electrical connections e Ifthe vehicle is fitted with a lighting system then always be careful when removing the electronics compartment cover so as not to rip the wires off of the circuit board WARNING Danger of fire exists if the fuse is D m 4 incorrectly assembled T ET 3 e Only ever assemble the fuse in the order shown in the ie Ee illustration at right Zei sall e Always tighten nuts to between 3 3 and 3 5 Nm Until 03 2004 After 03 2004 1 Fuse 1 Fuse 2 Fuse compartment 2 Fuse compartment 3 Washer 3 Nut DIN 6923 4 Nut M5 e Use the flat bladed screwdriver to carefully pry the rear plastic cover off as shown in the picture Remove the cover e Place it aside carefully The electrical connectors do not need to be removed from the circuit board for the lights Open the lid of the fuse compartment 1 If the main fuse is burnt out then first i determine what caused this Only when the A problem has
10. ctly dimensioned washers or spacers e Cable binders which have been cut off during disassembly should be replaced with new ones during reassembly e After completing maintenance work and before operating the electric vehicle make sure all fixations are correctly secured Check all parts for correct interlocking1 e Only operate the electric vehicle with correct tyre pressure see Technical Specifications e Check electrical components for correct functioning incorrect polarity of cables can result in damage to the electronics e Asa last check always carry out a test drive Notes Mark all current settings for the electric vehicle seat armrests backrest etc and the cable connecting plugs associated before any removals This makes reassembly easier All plugs are fitted with mechanical safety devices which prevent release of the connecting plugs during operation To release the connecting plugs the safety devices must be pressed in When reassembling ensure that these safety devices are correctly engaged 10 A WARNING Any alteration to the drive programme can influence vehicle handling and the tipping stability of the electric vehicle Alterations to the drive programme may only be carried out by trained Invacare dealers Invacare supplies all electric vehicles from the factory with a standard drive programme Invacare can only assume a warranty for the safe vehicle handling of the electric vehicle in
11. cts and gt Clean contacts and See Replacing terminals for corrosion terminals batteries on page 30 for Safety Information on working with batteries Walking Beam Check spring for Replace if damaged See Replacing Gamage Replace spring guides if ee Check that the bolts damaged Spring SE plastic guides on that hold the spring page 48 guides have become loosened Lifter Check correct function Repair if necessary Check function of the Stability Lock Check the programme e Update the software See Updating the version of the driving on page 41 electronics Is there a newer version available Driving Programme C Remote Remote Evaluate flash code electronics status display blinking Z ghem replace Fixing Replace Cable connecting plug E EISCHEN Replace cable connector Power supply plug or console 15 6 1 1 16 Operational Faults Troubleshooting the Tornado with ACS If a problem occurs with the wheelchair then please proceed as follows e Identify the possible cause of the fault by using the troubleshooting tables below e Check the Status Display on the remote Identify the error code if it is flashing e Perform the necessary checks and repairs as recommended in the table below Diagnosing driving faults PROBLEM OTHER SYMPTOMS POSSIBLE CAUSE SOLUTION REFERENCE Wheelchai r will not drive Status display on remote lights up normally and does not show an e
12. drive drive motors on page defective motor s 25 Batteries None Batteries may e Replacethe See Replacing cannot be be defective batteries batteries on page 30 charged LEDs on the Charger may e Replace the See User Manual of the charger are be defective charger charger flashing Wheelchai Status display Seat lifter is not e Return seat See User Manual r drives on remote in driving lifter to too slowly flashes 2x position either driving drive mode too high or too position display shows u low and has activated the automatic speed reduction Speed e Adjust the See Adjusting and reduction micro switch replacing the speed micro switch on the seat lifter may be badly adjusted reduction switch on page 43 None Remote may be defective Batteries may be defective e Replace the remote e Replace the batteries See Replacing the ACS Remote on page 39 See Replacing batteries on page 30 17 6 1 2 Diagnosing problems with electric actuators 18 In case an electric actuator will not function identify the source of the problem using the following table PROBLEM OTHER Electric Actuator does not function POSSIBLE SOLUTION REFERENCE SYMPTOMS CAUSE Remote CLAM is e Replace the See Replacing displays a defective CLAM components of the ACS flashing E or Shark electronics on status diode on page 28 the CLAM does not go out even if th
13. e assemble all components in reverse order 29 Vd 30 Replacing batteries CAUTION Risk of chemical burns e Please look out for damaged batteries or ensure that you do not damage the batteries Leaking acid can cause chemical burns to the skin and eyes e If acid should come into contact with the skin rinse immediately using plenty of freshwater e If acid should get into the eyes rinse immediately using plenty of fresh water and consult a physician CAUTION Danger of crushing e Secure the lifter against unintentional folding by using the mechanism intended for this purpose e Check whether the battery belts are damaged and lift the batteries carefully CAUTION Risk of fire and burns if battery poles are short circuited e When replacing the batteries the battery poles MUST NOT come into contact with metal parts of the wheelchair causing bridging e Be sure to replace the battery pole caps after the batteries have been replaced CAUTION Environmental contamination e Used batteries should not be disposed of with domestic waste or outdoors Please dispose of the batteries professionally by giving them to your local harmful substance point of acceptance Pre requisites 11mm open jawed wrench 5mm and 6mm hexagon socket Diagonal nosed cutting pliers Rubber hammer Water resistant marker Cable binder Replacement battery ies Optional new battery belts Large flat screwdriver P
14. e remote is switched off or disconnected None Cable may e Check that See Checking the be the cable is cables on page 38 disconnected not or damaged disconnected or damaged If necessary replace the cable Electric e Test the See Testing an actuator actuator may actuator motor on page 42 be defective Remote may e Exchange See Replacing the ACS be defective the remote Remote on page 39 on the wheelchair for a different one to eliminate the possibility that the remote may be the cause 6 1 3 REM24 Error Codes and Diagnostic Codes The drive electronics are capable of rectifying some errors automatically In this case the status display will cease to flash Please switch the remote on and off several times Wait approx 5 seconds each time before switching the remote on again If this does not rectify the error locate the error using the flash codes shown below FLASHCODE MEANING SOLUTION DOCUMENTATION 1 Module defective e Replace defective See Replacing module components of the ACS or Shark electronics on page 28 2 Accessory error e g e Check accessory See Testing an actuator short circuit connections check actuator motor on accessories page 42 Lifter raised or lowered e f lifter is raised See User Manual too far seat not at driving lower in stages height until the status display stops flashing If lowered too far raise lifter in stages until the
15. eels e Use the flat bladed screwdriver to carefully pry the rear plastic cover off as shown in the picture e Prop up the wheelchair by lifting it up on the side that you want to work on and then placing the wooden block underneath the battery box on that side e Loosen and remove the 19 mm nut 1 that holds the castor wheel using the socket wrench Hold the wheel so it does not rotate while removing the nut e Pull the steering head shaft down and out of the steering head tube e Remove the washer and the bearing race from the top of the tube The other bearing race should be on the shaft IMPORTANT REASSEMBLY INFORMATION The pictures show the wide rim on the outside of the bearing race O A and the narrow rim on the inside B The bearings must always be assembled so that the narrow rims are facing each other inwards The steering head bolt and the nut must always press against the wide rims from the outside Otherwise the bearings will be forced out apart by the pressure of the bolt 46 The steering wheels should swivel freely after assembly but there should be no play in the bearings e First tighten the nut to 20 Nm 2 Nm e Loosen the nut a little e Retighten to 15 Nm 1 5 Nm 47 7 12 amp 48 Replacing the Anti Dive Spring and or its plastic guides CAUTION Danger of the wheelchair tipping over or rolling away e Secure the wheelchair from tipping over by propping it u
16. foam block underneath Insert the hexagon socket 5mm through the bore and unscrew the rear bolts 1 on the drive suspension Remove the drive unit from the suspension in a downward direction Unscrew the six screws 1 on the bedding plate CAUTION Fire hazard Cables can be pinched and chafed Please ensure correct cable layout The motor cable must be secured on the panelling by means of a plastic ring and may not protrude into the lifter area The drive unit is installed in reverse order 27 7 3 Replacing components of the ACS or Shark electronics Al Requirements e Large flat bladed screwdriver e Phillips screwdriver e Hexagonal socket head key 4 mm e Use the flat bladed screwdriver to carefully pry the plastic cover off as shown in the picture The picture at right shows the positions of the CLAM and the Power Module of the ACS System The Shark Power Module is located in exactly the same position as it s ACS counterpart 1 CLAM or Lighting Module 2 Power Module partly hidden by cables e Remove all electrical connectors from the module that needs to be replaced 28 If replacing the Power Module ACS or Shark Remove the hexagonal socket head screws 1 on both sides of Power Module f Pull the Module up and out If replacing the CLAM Lighting Module e Detach the CLAM from it s holder by simply pulling it upwards Replace the defective module and r
17. for any loose connections or damage Siehe Checking the cables on page 38 Remote may be faulty Various causes e Change the remote on the wheelchair to be able to exclude the remote being the cause of the fault See Replacing the ACS Remote on page 39 e Analyse error code See Shark error codes and diagnostic codes on page 23 21 22 PROBLEM OTHER POSSIBLE e SOLUTION DOCUMENTATION SYMPTOMS CAUSE Wheelchair None Batteries may be e Replace the batteries See Replacing jerky in faulty instable batteries on page drive voltage 30 operation Actuation e Replace motor s Siehe Replacing motor s may be the drive motors faulty on page 25 Batteries None Batteries may be Replace batteries See Replacing not being faulty batteries on page charged 30 LEDs flashing on Charger may be Replace charger See operating charger faulty instructions for battery charger Wheelchair None Batteries may be e Replace batteries See Replacing drives too faulty batteries on page slowly 30 6 2 2 Shark error codes and diagnostic codes The actuation electronics can automatically remedy certain disorders In this case the status display will stop flashing Please switch the remote on and off several times Please wait about 5 seconds every time before switching the remote on again H the error is not remedied by this please diagnose the cause on the basis
18. fr invacare com France WWW www invacare fr GB Invacare Ltd Customer Service 44 0 1656 776 200 Side Pencoed Technology Park Pencoed Bridgend CF35 5HZ United Kingdom Fax Customer Service WWW 44 0 1656 776 201 uk invacare com eire invacare com www invacare co uk ht Invacare Mecc San s r l Via Dei Pini 62 36016 Thiene VI ITALIA Invacare Ireland Ltd Unit 5 Seatown Business Campus Seatown Rd Swords County Dublin Ireland B Fax WWW B Fax WWW 39 0445 38 00 59 39 0445 38 00 34 italia invacare com www invacare it 353 18 10 70 84 353 18 10 70 85 eire invacare com www invacare ie Invacare AS E K Kundeservice 47 0 22 57 95 00 Grensesvingen 9 Fax Kundeservice 47 0 22 57 95 01 Postboks 6230 norway invacare com Etterstad WWW www invacare no N 0603 Oslo Norge NL Invacare B V a 31 0 318 69 57 57 Celsiusstraat 46 Fax 31 0 318 69 57 58 NL 6716 BZ Ede nederland invacare com Nederland WWW www invacare nl r ps Invacare Portugal Lda a 351 225 1059 46 _ Rua Estrada Velha 949 a 351 225 1059 47 P 4465 784 Lega do Balio Fax 351 225 1057 39 Portugal portugal invacare com WWW www invacare pt Ce terf rs ljare Invacare AB i EIN Fagerstagatan 9 5 163 91 Sp nga Sverige Tillverkare Invacare Deutschland GmbH KleiststraRe 49 D 32457 Porta Wes
19. hassis Push the regulating motor 2 together with the nest into the chassis and allow to lock into place in the bottom plate Secure using lateral Allen screws Apply the front panelling 1 and secure using lateral Allen screws Screw the battery cable onto the plus and minus pole Slide the pole caps over the poles Plug all cables into the electronic components until you hear a slight click CAUTION Danger of crushing Please ensure that the regulating motor slides into the upper guiding device Move the regulating motor to the uppermost position and ensure that it slides into the upper guiding device 1 Raise the lifter slightly and unlock the retaining mechanism 1 The entire lifter load is now on the regulating motor again Test all vehicle functions Check the charge status of the new batteries and charge fully 35 7 5 d 36 Replacing the main fuse If the main fuse is burnt out then this almost certainly indicates a short circuit in the battery cables If the cause is not a battery cable then there may be a short circuit inside the power module This is very unlikely but can occur under extreme conditions such as when the wheelchair has been cleaned using a high pressure cleaning device Needless to say using such a device against Invacare s strong recommendation not to in the User Manual will void the warranty CAUTION Danger of fire e Only ever use a fuse with the corre
20. he ACS Remote on page 39 23 24 FLASHING Meaning Solution FLASHING CODE CODE 8 Fault on Shark e Check all cables and connectors on See Checking the main module the Shark system cables on page e Replace the main module 3 See Replacing components of the ACS or Shark electronics on page 28 9 Communication e Check all cables and connectors on See Checking the error on the Shark the Shark system cables on page system 38 e Replace the remote See Replacing the ACS Remote on page 39 10 Unknown error e Check all cables and U connectors See Checking the cables on page 38 11 Incompatible e Anincorrect remote has been See Replacing remote connected Ensure that main module the ACS Remote and remote code are concordant on page 39 See Replacing components of the ACS or Shark electronics on page 28 gt pe 7 2 W Repair Work General warning information on installation work CAUTION Danger of injury The edges of the plastic panelling are sharp e Be particularly careful when installing and dismantling panelling parts CAUTION Risk of damage to the vehicle Collisions can be caused if shim rings are removed from the drive wheels during installation work e Shim rings are frequently placed between the drive shaft and the wheel hub to compensate tolerances Collisions can be caused if these shim rings are removed and not re installed Please install all shi
21. igns of damage and crushing e Be careful with every connector It must not come away from the bush e lf aconnector is loose use slight pressure to press the connector into the bush It must lock into place e Check whether the connector is fitted firmly into the bush If not please repeat the preceding work step e Close the electronic panelling In doing so push the rear side panelling away slightly using a large flat screwdriver e Check all vehicle functions 7 7 d Replacing the ACS Remote Pre requisites e Phillips screwdriver e To modify a drive programme you will need Programming software or a Handheld Programmer and the Installation Manual of the ACS Electronics available from Invacare NOTE All ACS remotes are supplied with a standard drive programme If the driving programme has been customised then you will have to perform this customisation again after installing the new electronic module WARNING Every alteration to the drive programme can influence vehicle handling and the tipping stability of the wheelchair e Alterations to the drive programme must only be carried out by trained Invacare dealers Invacare can only assume a warranty for the safe vehicle handling of the wheelchair in particular tipping stability for unaltered standard drive programmes e Switch off the remote e Pull the bus cable 1 out of the remote e Loosen the thumb screw 2 e Pu
22. lease note It is easier to carry out a few work steps with the assistance of another person in particular when lifting the lifter and unlocking the retaining mechanism Move the lifter to the uppermost position Raise the lifter further by pulling the piston rod of the actuator towards the front to unfasten the piston rod head from its socket and simultaneously pulling the seat upwards so that the retaining mechanism 1 locks into place Check whether the retaining mechanism 1 is fully locked into place Move the regulating motor to the lowest position The regulating motor slides out of the upper guiding device Use a 5mm or 6mm hexagon socket to unscrew the screws 1 and 2 on both sides of the vehicle Remove the front panelling to the front Open the plug in connection on the regulating motor cable Pull the nest together with the regulating motor slightly to the front 1 and then lift 2 Now remove the regulating motor and the nest completely 31 e Open the electronic panelling In doing so push the rear side panelling away slightly using a large flat screwdriver A CAUTION Electronics can be damaged e Disconnect all electronic components from the batteries before commencing work on the batteries A short circuit during the following work could otherwise damage the electronics e Disconnect all plugs from the electronic components O Please note Please make a note of the
23. ll the remote and the remote holder out of the guiding device e Unscrew both remote holder screws 1 using the crosstip screwdriver 39 40 Installation of the remote is carried out in reverse order Update the software in case a newer version is available Customise the driving programme with the programming software if required Check all vehicle functions 7 8 Vd Updating the driving program The driving programs for electric wheelchairs are continually updated and improved by Invacare For this reason you should check whether the version number is still up to date each time a wheelchair comes in for repairs and also during regular inspections If a newer version is available the driving program must be updated The procedure for updating the driving program is described in the user manual of the Wizard software NOTE The electronic system is supplied with a standard drive program If the driving program has been customised you have to perform this customisation again after installing the new driving program WARNING Every alteration to the drive program can influence vehicle handling and the tipping stability of the wheelchair e Alterations to the drive program must only be carried out by trained Invacare dealers e Invacare can only assume a warranty for the safe vehicle handling of the wheelchair in particular tipping stability for unaltered standard drive programs P
24. m rings in exactly the same positions they were in before dismantling Replacing the drive motors Find out here how to replace the Tornado drive motors CAUTION Danger of tipping over and crushing e Secure the vehicle with wedges and a jack up device to prevent it rolling and tilting as it tends to do this following removal of a drive wheel Pre requisites e Large screwdriver e 5mm and 6mm hexagon socket e Diagonal nosed cutting pliers e Material for jacking up the vehicle Please note Please pay attention to the plain washers during dismantling Put small parts aside in such a way that they can be re fitted in the correct order e Jack up the vehicle for instance by placing a block of wood under the chassis e Loosen the wheel nut 1 using a 5mm hexagon socket e Remove the Allen screw and the hub cap e Pull the complete wheel from the wheel hub 25 26 Loosen the screws 1 using a 6mm hexagon socket and remove the outer side panelling Loosen the turn lock fasteners 1 and remove the inner side panelling Remove the securing ring 1 and release the uncoupling rod assembly from the drive unit Open the electronic panelling pushing the rear side panelling away slightly using a large flat screwdriver Pull the motor plug 1 for the right hand or left hand drive out of the electronics Secure the drive unit against falling out by placing a wooden block or styro
25. n both sides For this reason there is only one correct way to fit them It is imperative that you observe the reassembly information A Requirements de e Socket wrench 19 mm e Torque wrench 7 11 1 Front Castor Wheels e Release the plastic clips 1 that hold the shroud e Pull the shroud outwards and forward to remove 44 e Prop the wheelchair up on the side that you want to change the bearings on by placing an object underneath the drive wheel e Loosen and remove the 19 mm nut using the socket wrench Hold the wheel so it does not rotate while removing the nut e Pull the steering head shaft down and out of the steering head tube e Remove the washer and the bearing race from the top of the tube The other bearing race should be on the shaft IMPORTANT REASSEMBLY INFORMATION E The pictures show the wide rim on the outside of the bearing race A A and the narrow rim on the inside B The bearings must always be assembled so that the narrow rims are facing each other inwards The steering head bolt and the nut must always press against the wide rims from the outside Otherwise the bearings will be forced out apart by the pressure of the bolt The steering wheels should swivel freely after assembly but there should be no play in the bearings e First tighten the nut to 20 Nm 2 Nm e Loosen the nut a little e Retighten to 15 Nm 1 5 Nm 45 7 11 2 Rear Castor Wh
26. n work READ WELL BEFORE OPERATION This symbol advises you to read information carefully 2 1 Safety and assembly instructions These safety instructions are intended to prevent accidents during work and it is imperative that they are observed Before any inspection or repair work e Read and observe this repair manual and the associated operating manual e Observe the minimum requirements for carrying out the work see chapter entitled General information General safety information and notes on assembly disassembly Danger of injury by crushing e Please note the heavy weight of some components This applies especially to removal of drive units and batteries e Prop up the lifted electric vehicle with appropriate supports before starting the disassembly or assembly Danger of fire and burns due to electrical short circuit e The electric vehicle must be switched off before removal of voltage carrying components To do this disconnect the batteries e When making measurements on voltage carrying components avoid short circuiting the contacts Danger of fire and combustion Danger of injury and damage to the vehicle can result from incorrect or incomplete maintenance e Only ever use tools which are undamaged in good condition e Some moving parts have Teflon bushings These parts must never be lubricated with grease e Never use standard nuts instead of self locking nuts e Always use corre
27. ng and wide enough Using a wooden block that is too short or too high could cause the wheelchair to tip over e Switch the wheelchair off at the remote CAUTION Injury hazard If the wheel has been insufficiently tightened during assembly it may become loosen during driving e When reassembling the drive wheels tighten the TORX screws to a torque of 35 Nm e Secure all screws using a suitable threadlocker Requirements e TORX screwdriver TX40 Note Pay attention to small pieces and the order in which the components are disassembled Arrange them in an orderly fashion so they can easily be assembled again in the right order e Prop up the wheelchair by lifting it up on the I side that you want to work on and then placing the wooden block underneath the battery box on that side e Unscrew the 4 screws that hold the wheel 1 using the TORX screwdriver TX40 e Remove the wheel from the hub e Reassembly is done in reverse order 7 15 Replacing the safety belt A4 Requirements se e 10mm socket spanner e 4mm Allen key Dismantling the safety belt e Remove the plastic cap 5 e Loosen the bolt 3 and the associated nut in the figure this is covered with a 4 mm Allen key and a 10 mm socket spanner e Remove the nut incl the washer e Remove the screw incl the safety belt the washer 2 and the washer arranged behind Note i Another nut is fixed between the two washers
28. o a requirement Special Invacare training sessions are recommended e Alterations to the electric vehicle which occur as a result of incorrectly or improperly executed maintenance or overhaul work lead to the exclusion of all liability on the part of INVACARE e Ifyou have any problems or questions please contact INVACARE SERVICE Notes on transport e If the electric vehicle has to be shipped back to the manufacturer for major repairs you should always use the original packaging for transport e You should also include as accurate a fault description as possible Important symbols in this manual WARNING This symbol warns you of danger e Always follow these instructions to avoid injury to the user or damage to the product EXPLOSION HAZARD This symbol warns you of an explosion hazard which for example can be caused by excessive tyre pressure in a pneumatic tyre e Always follow the instructions to avoid injury to the user or damage to the product BURN HAZARD This symbol warns you of burns due for example to leaking battery acid e Always follow the instructions to avoid injury to the user or damage to the product NOTE This symbol identifies general information which is intended to simplify working with your product and which refers to special functions Requirements e This symbol identifies a list of various tools components and items which you will need in order to carry out certai
29. on the following flashing codes FLASHING CODE 1 Meaning Operational error Battery error Solution Please ensure that the joystick is in neutral central position simply release joystick and switch on again Check battery and power cable FLASHING CODE See Checking the cables on page 38 Charge batteries If you switch the wheelchair off for a few minutes the batteries are often able to re charge sufficiently to enable a short journey You should however only use this solution in an emergency as this leads to the batteries discharging excessively Replace the batteries See operating instructions See Replacing batteries on page 30 Error on the left motor M2 Check the motor cable and U connector Check the motor See Checking the cables on page 38 See Replacing the drive motors on page 25 Error on the right motor M1 Check the motor cable and U connector Check the motor See Checking the cables on page 38 See Replacing the drive motors on page 25 Fault on the left M2 motor brake Check cable and connector See Checking the cables on page 38 Fault on the right M1 motor brake Check cable and connector See Checking the cables on page 38 Fault on the Shark remote Check the bus cable on the remote and U connector Replace the remote See Checking the cables on page 38 See Replacing t
30. p with a wooden block under the battery box that is long and wide enough Using a wooden block that is too short or too high could cause the wheelchair to tip over e Switch the wheelchair off at the remote Requirements e 13mm open ended wrench e 5 mm Allen key e 6 mm Allen key Note Pay attention to small pieces and the order in which the components are disassembled Arrange them in an orderly fashion so they can easily be assembled again in the right order e Prop up the wheelchair by lifting it up on the side that you want to work on and then placing the wooden block underneath the battery box on that side 1 e Use the 5 mm Allen key to loosen and remove the screw that holds the wheel 2 e Pull the wheel off the axle e Use the 6 mm Allen key to loosen and remove the bolts 1 that hold the outer shroud e Release the rear plastic clip 2 that attaches i the inner and outer shrouds e Remove the outer shroud Release the forward plastic clip 1 that holds the inner shroud Remove the inner shroud Use the 6 mm Allen key and the 13 mm open ended wrench to remove the lower bolt 1 that attaches the Walking Beam and the steering head tube of the front castor wheel Use the 13 mm open ended wrench to remove the bolt 1 that holds the lower plastic guide of the anti dive spring The two halves of the Walking Beam can now be moved independently from each other Lift the upper part
31. re requisites e Dynamic Wizard software e User manual for the Wizard software e For further information on other requirements such as the minimum system configuration of the PC to be used for programming necessary programming cables see the user manual of the Wizard software You find the latest version of the user manual in the download area on http www dynamiccontrols com 41 7 9 Testing an actuator motor Al Requirements IS e Multimeter e Check the electrical resistance of the actuator If it is close to infinite then the motor is likely to be burnt out If it is less than 1Q then motor has a short circuit In either case the motor needs to be replaced 42 7 10 Adjusting and replacing the speed reduction switch Find out here how you can adjust and replace the switch that reduces the speed when in the upper lifter position Yl Pre requisites FS e Small pliers e Move the lifter to the upper and lower position several times In doing so check whether the contact switches e Ifthe contact does not switch bend the plate 1 slightly e If the contact is faulty replace the entire cable harness e Check all vehicle functions 43 7 11 Replacing the steering head bearings on the front or rear castor wheels A CAUTION Incorrect reassembly can damage the bearings or cause the steering wheels to fall out e The single row angular ball bearing races are not the same o
32. rror code Status display on remote does not light up Drive motors may be disengaged Batteries may be defective Batteries may be completely discharged Power supply to the remote may be interrupted Engage the drive motors Replace the batteries Charge the batteries Check the main fuse Check cables between modules for loose connections or damage See User Manual See Replacing batteries on page 30 See User Manual See Replacing the main fuse on page 36 See Checking the cables on page 38 Remote may be defective Exchange the remote on the wheelchair for a different one to eliminate the possibility that the remote may be the cause See Replacing the ACS Remote on page 39 Status display on remote is flashing Various causes Identify the error code See REM24 Error Codes and Diagnostic Codes on page 19 PROBLEM OTHER SYMPTOMS Status display on remote flashes 2x drive mode display shows POSSIBLE CAUSE Speed reduction switch on the lifter may be defective or disconnected SOLUTION e Replace cable or switch REFERENCE See Adjusting and replacing the speed reduction switch on page 43 Wheelchai None Batteries may e Replacethe See Replacing r does not be defective batteries batteries on page 30 drive voltage not smoothly stable Drive motor s e Replace the See Replacing the may be
33. s of the ACS or Shark electronics on page 28 11 Motors overloaded e Switch remoteon overheated and off wait if necessary 12 Module used has e Remove incorrect See Replacing compatibility problems module components of the ACS or Shark electronics on page 28 6 2 6 2 1 Operational faults on a wheelchair fitted with Shark electronics Please proceed as follows in the event of operational faults e First of all analyse the possible cause of the disorder on the basis of the following tables e Check the status display on the remote Analyse the flashing error code e Carry out the necessary checks and repairs as recommended in the following table Diagnosis of actuation disorders PROBLEM OTHER SYMPTOMS POSSIBLE CAUSE e SOLUTION Wheelchair will not start up Status display on the remote illuminated as normal and does not indicate a disorder code Status display on the remote is not illuminated Status display on remote flashing Actuation motors may be disengaged Batteries may be faulty e Clutch in actuation motors DOCUMENTATION See operating instructions e Replace the batteries See Replacing batteries on page 30 Batteries may be almost empty e Charge batteries See User Manual Power supply to the remote may be interrupted e Check the main fuse See Replacing the main fuse on page 36 e Check the cable between the modules
34. stening Side panel damage and fixing Cushion Check seat angle adjustment Damage and seams Fixings Check cabling Check function Check drive wheels for tight fit and side play Check steering wheels for tight fit float side play and correct torque 15 Nm 1 5 Nm Check pneumatic tyres on the drive wheels Check functions in drive and push modes Check disengager Check welded seams interlocking screws footplates Check cabling Check contacts Check functions Check cabling Check function Check batteries for damage Tighten screws replace padding if damaged Tighten screws replace side panels if damaged Replace covers upholstery if damaged Replace parts if damaged Replace parts if damaged gt Tighten screws Replace cable or motor if necessary Adjust replace wheel hubs Replace wheels wheel fork or wheel bearings Repair or replace if damaged Replace motor if necessary Tighten screws nuts adjust or replace if necessary gt Tighten replace if necessary Replace cable if necessary Replace bulbs or cables if necessary Replace batteries if necessary See Replacing a drive wheel on page 52 See Replacing the steering head bearings on the front or rear castor wheels on page 44 See Repairing a flat tyre on page 50 See Replacing batteries on page 30 Component Check Action Notes Check conta
35. tfalica Deutschland T Kundtj nst Fax Kundtj nst WWW M LNDAL a Fax LANDSKRONA a Fax OSKARSHAMN a Fax 46 0 8 761 70 90 46 0 8 761 81 08 sweden invacare com finland invacare com www invacare se 46 0 31 86 36 00 46 0 31 86 36 06 ginvacare invacare com 46 0 418 285 40 46 0 418 180 89 linvacare invacare com 46 0 491 101 40 46 0 491 101 80 oinvacare invacare com Table of Contents Chapter 1 INTRODUCTION 1 1 General information 1 2 Notes on transport 1 3 Important symbols in this manual 2 SAFETY AND ASSEMBLY INSTRUCTIONS 2 1 Before any inspection or repair work 2 2 General safety information and notes on assembly disassembly 3 TIGHTENING TORQUES 4 LAYOUT OF COMPONENTS AND MODULES 5 SERVICE PLAN 1X ANNUALLY 6 OPERATIONAL FAULTS 1 Troubleshooting the Tornado with ACS 6 1 1 Diagnosing driving faults 6 1 2 Diagnosing problems with electric actuators 6 1 3 REM24 Error Codes and Diagnostic Codes 6 2 Operational faults on a wheelchair fitted with Shark electronics 6 2 1 Diagnosis of actuation disorders 6 2 2 Shark error codes and diagnostic codes 7 REPAIR WORK 7 14 General warning information on installation work 7 2 Replacing the drive motors 7 3 Replacing components of the ACS or Shark electronics 7 4 Replacing batteries 7 5 Replacing the main fuse 7 6 Checking the cables 11 12 14 25 25 25 28 3
36. which is still attached to the steering head tube of castor wheel to release the pressure on the anti dive spring 1 Replace the anti dive spring and or the plastic guide s if necessary Reassembly is done in reverse order 49 7 13 50 Repairing a flat tyre CAUTION Danger of the wheelchair tipping over or rolling away e Secure the wheelchair from tipping over by propping it up with a wooden block under the battery box that is long and wide enough Using a wooden block that is too short or too high could cause the wheelchair to tip over e Switch the wheelchair off at the remote CAUTION Injury hazard If the wheel has been insufficiently tightened during assembly it may become loose during driving e When reassembling the drive wheels tighten the TORX screws to a torque of 35 Nm e Secure all screws using a suitable threadlocker Requirements e TORX screwdriver TX40 Allen key 5mm Repair kit for tyre repair or a new inner tube Talcum powder Threadlocker such as Loctite 243 Note Pay attention to small pieces and the order in which the components are disassembled Arrange them in an orderly fashion so they can easily be assembled again in the right order e Prop up the wheelchair by lifting it up on the side that you want to work on and then placing the wooden block underneath the battery box on that side e Unscrew the 4 screws that hold the wheel 1 using the TORX
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